EJC 212 / 214 / 216 / 220 05.08 - Operating instructions 51102242 02.11 EJC 212 EJC 214 EJC 216 EJC 220 G
Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type Option Serial no. Year of manufacture EJC 212 EJC 214 EJC 216 EJC 220 Additional information On behalf of Date G EU Conformity Declaration The undersigned hereby declare that the powered industrial truck described below in detail complies with the European Directives 2006/42/EC (Machinery Directive) and 2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well as the legislative decree to incorporate the directives in national law. The signatories are in each case individually authorized to compile the technical documents. 3
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WARNING! Unsuitable batteries that have not been approved by Jungheinrich for the truck can be hazardous The design, weight and dimensions of the battery have a considerable effect on the operational safety of the truck, in particular its stability and capacity. The use of unsuitable batteries that have not been approved by Jungheinrich for the truck can lead to a deterioration of the braking system during energy recovery operations and also cause considerable damage to the electrical control system. The use of batteries that have not been approved by Jungheinrich can therefore affect the health and safety of personnel. Only manufacturer-approved batteries may be used on the truck. Replacement of the battery equipment requires the manufacturer's agreement. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck. Do not use batteries that have not been approved by the manufacturer. EN
Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously. The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions. Safety notices and text mark-ups Safety instructions and important explanations are indicated by the following graphics: DANGER! Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death. WARNING! Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death. CAUTION! Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury. Z NOTE Indicates a material hazard. Failure to comply with this instruction may result in material damage. Used before notices and explanations. t Indicates standard equipment o Indicates optional equipment Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. 5
Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com 6
Table of Contents A Correct Use and Application... 11 1 General... 11 2 Correct application... 11 3 Approved application conditions... 11 4 Proprietor responsibilities... 12 5 Adding attachments and/or accessories... 12 B Truck Description... 13 1 Application... 13 1.1 Truck models and rated capacity... 13 2 Assemblies and Functional Description... 14 2.1 Assembly Overview... 14 2.2 Functional Description... 16 3 Technical Specifications... 17 3.1 Performance data... 17 3.2 Dimensions... 18 3.3 Weights... 21 3.4 Tyre type... 21 3.5 EN norms... 22 3.6 Conditions of use... 23 3.7 Electrical requirements... 23 4 Identification points and data plates... 24 4.1 Data plate... 25 4.2 Truck load chart... 26 C Transport and Commissioning... 27 1 Lifting by crane... 27 2 Transport... 28 3 Using the Truck for the First Time... 29 D Battery - Servicing, Recharging, Replacement... 31 1 Safety Regulations Governing the Handling of Lead-Acid Batteries... 31 2 Battery types... 33 3 Exposing the battery... 34 4 Charging the battery... 35 4.1 Charging the battery with an on-board charger... 35 4.2 Charging the battery with a stationary charger... 39 5 Battery removal and installation... 40 5.1 Removing the battery from the side... 41 7
E Operation... 43 1 Safety Regulations for the Operation of the Forklift Truck... 43 2 Displays and Controls... 44 2.1 Battery discharge indicator... 47 3 Starting up the truck... 48 3.1 Checks and operations to be performed before starting daily operation. 48 3.2 Preparing the truck for operation... 49 3.3 Parking the truck securely... 51 3.4 Battery discharge monitor... 51 4 Industrial Truck Operation... 52 4.1 Safety regulations for truck operation... 52 4.2 Emergency Disconnect, Travel, Steering, Braking... 54 4.3 Lifting, transporting and depositing loads... 59 5 Troubleshooting... 62 5.1 Truck does not start... 62 5.2 Load cannot be lifted... 62 6 Operating the truck without its own drive system... 63 7 Load handler emergency lowering... 64 8 Optional equipment... 65 8.1 CanCode keypad... 65 8.2 Setting the truck parameters with CanCode... 70 8.3 Parameters... 72 8.4 CANDIS display instrument... 76 8.5 ISM access module (o)... 77 F Industrial Truck Maintenance... 79 1 Operational Safety and Environmental Protection... 79 2 Maintenance Safety Regulations... 79 3 Servicing and Inspection... 84 4 Maintenance checklist... 85 4.1 Owner... 85 4.2 Customer Service... 86 5 Lubricants and Lubrication Schedule... 90 5.1 Handling consumables safely... 90 5.2 Lubrication Schedule... 92 5.3 Consumables... 93 6 Maintenance and repairs... 94 6.1 Preparing the truck for maintenance and repairs... 94 6.2 Removing the front panel... 94 6.3 Removing the drive panel... 95 6.4 Checking the hydraulic oil level... 96 6.5 Check the gear oil level... 97 6.6 Replacing the gauze filter, flushing the gauze filter... 97 6.7 Replace the filter cartridge... 98 6.8 Checking electrical fuses... 99 6.9 Restoring the truck to service after maintenance and repairs... 100 7 Decommissioning the industrial truck... 101 8
7.1 Before taking the truck out of service... 101 7.2 Action to be taken during decommissioning... 102 7.3 Restoring the truck to service after decommissioning... 103 8 Final de-commissioning, disposal... 103 9 Safety tests to be performed at intervals and after unusual incidents... 104 9
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Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions. 0506.GB 1
2 0506.GB
A Correct Use and Application 1 General The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property. 2 Correct application NOTE The maximum load and load distance are indicated on the load chart and must not be exceeded. The load must rest on the load handler or be lifted by an attachment approved by the manufacturer. The load must rest on the back of the fork carriage and centrally between the forks. Lifting and lowering of loads. Transporting lowered loads. Do not travel with a raised load (>500 mm). Do not carry or lift passengers. Do push or pull load units. 3 Approved application conditions Z Operation in industrial and commercial environments. Permissible temperature range 5 C to 40 C. Operation only on secure, level surfaces with sufficient capacity. Operation only on routes that are visible and approved by the proprietor. Negotiating inclines up to a maximum of 15 %. Do not negotiate inclines crosswise or at an angle. Transporting loads downhill. Operation in partially public traffic. Special equipment and authorisation are required if the truck is to be used in extreme conditions. The truck is not authorised for use in areas at risk of explosion. 11
4 Proprietor responsibilities For the purposes of the present operating instructions the proprietor is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user and third parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all users have read and understood these operating instructions. NOTE Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer. 5 Adding attachments and/or accessories Adding accessories The mounting or installation of additional equipment which affects or enhances the performance of the forklift truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval does not however constitute the manufacturer s approval. 12
B Truck Description 1 Application The EJC 212 / 214 / 216 / 220 is a four-wheel, tiller-operated electric stacker with a steered drive wheel. It is designed for use on level floors to lift and transport goods. Open bottom pallets or roll cages can be lifted. 1.1 Truck models and rated capacity The rated capacity depends on the model. The rated capacity can be derived from the model description. EJC212 EJC Model name 2 Series 12 Rated capacity x 100 kg The rated capacity does not generally match the permissible capacity. The capacity can be found on the load chart attached to the rack. 13
2 Assemblies and Functional Description 2.1 Assembly Overview 1 7 9 3 3 4 2 5 6 8 10 11 12 13 14 16 17 15 Item EJC 212-220 Component 1 t Mast 2 t Mast guard o Load backrest (for Cold store application) 3 t Travel switch 4 t Collision safety switch 5 t Battery cover 6 t Emergency Disconnect (battery connector) 7 t Slow travel button 8 t Forks 14
9 t Tiller 10 t Battery charge / discharge unit o CANDIS display instrument 11 o CANCODE keypad o ISM access module 12 t Key switch 13 o Charger 14 t Drive wheel 15 t Front panel 16 o Document storage compartment 17 t Castor wheel t= Standard version o= Optional equipment 15
2.2 Functional Description Safety mechanisms An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt. Pressing the Emergency Disconnect rapidly cuts out all electrical functions in hazardous situations. Hydraulic system Lifting and lowering are activated via the lift and lower buttons. When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder. If the truck is fitted with a duplex twin-stage mast (ZZ) or a triplex telescopic mast (DZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck. Drive system A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox. The electronic traction controller ensures smooth drive motor speed control and hence smooth travel, powerful acceleration and electrically controlled braking with energy regeneration. Tiller All travel and lift operations can be performed sensitively without having to reach. The driver steers with a tiller: The drive system can be pivoted +/- 90. Electric steering (o) The electric steering system is self-monitoring. The steering controller permanently monitors the entire steering system. If an error is detected the traction controller interrupts travel, brakes regeneratively and the magnetic brake is applied. Electrical system 24 volt system. Electronic traction control is standard. Controls and Displays Ergonomic controls ensure fatigue-free operation for sensitive application of the travel and hydraulic operations. The battery discharge indicator shows the available battery capacity. Mast The maximum strength steel sections are narrow, allowing for outstanding fork visibility in particular with the three-stage mast. The lift rails and the fork carriage run on permanently-lubricated and hence maintenance-free angled rollers. 16
3 Technical Specifications Z Technical data specified in accordance with 2198. Technical modifications and additions reserved. 3.1 Performance data Description EJC 212 EJC214 EJC 216 EJC 220 Q Rated capacity 1200 1400 1600 2000 kg Travel speed w / w.o. rated load 6,0 / 6,0 6,0 / 6,0 6,0 / 6,0 5,3 / 5,4 km/h Lift speed with / without rated load ZT ZZ DZ-1 0,16 / 0,26 0,15 / 0,24 0,15 / 0,24 0,15 / 0,26 0,14 / 0,24 0,14 / 0,24 0,14 / 0,26 0,1 / 0,18 0,14 / 0,24 0,1 / 0,16 0,14 / 0,24 m/s Lower speed with / without rated load DZ-2 ZT ZZ - 1 ZZ - 2 0,15 / 0,25 0,4 / 0,46 0,4 / 0,22 0,35 / 0,46 0,35 / 0,27 0,14 / 0,24 0,4 / 0,46 0,4 / 0,22 0,35 / 0,46 0,35 / 0,27 0,13 / 0,25 0,4 / 0,46 0,4 / 0,22 0,35 / 0,46 0,35 / 0,27 0,4 / 0,4 0,4 / 0,22 0,4 / 0,22 m/s DZ-1 0,40 / 0,46 0,4 / 0,46 0,4 / 0,46 Max. gradeability w / w.o. load DZ-2 10 / 16 9 / 16 8 / 16 5 / 16 % 17
3.2 Dimensions c l h 2 h 3 h 14 min. m 2 s Q l 2 l 1 y h 13 x e b 1 b 10 b 11 b 5 ( a/2 W a (l ) 6 a/2 A st 18
EJC 212 EJC 214 c Load centre distance 600 600 mm x Load distance 687 687 mm y Wheel base 1277 / 1357 1277 / 1357 mm h1 Mast height (retracted) ZT 1) 1750-2650 1750-2650 mm h1 Mast height (retracted) ZZ 1) 1700-2600 1700-2600 mm h1 Mast height (retracted) DZ 1) 1830-2250 1830-2250 mm h2 Free lift ZT 100 100 mm h2 Free lift ZZ 1223-2123 1227-1777 mm h2 Free lift DZ 1356-1776 1356-1776 mm h3 Lift (mast-dependent) ZT 2500-4300 2500-4300 mm h3 Lift (mast-dependent) ZZ 2500-4300 2500-4300 mm h3 Lift (mast-dependent) DZ 4090-5350 4090-5350 mm h4 Mast height extended ZT 2977-4777 2977-4777 mm h4 Mast height extended ZZ 2977-4777 2977-4777 mm h4 Mast height extended DZ 4565-5825 4565-5825 mm h13 Lowered height 90 90 mm h14 Tiller height in min./max. travel position 768 / 1298 768 / 1298 mm l1 Length 1896 / 1976 1896 / 1976 mm l2 Fork length 746 / 826 746 / 826 mm including fork shank b1 Truck width 802 802 mm b5 Width across forks 570 570 mm s/e/l Fork dimensions mm b10 Track width, front 510 510 mm b11 Track width, rear 375 375 mm m2 Ground clearance centre 30 30 mm wheelbase Ast Working aisle width with pallet 2364 / 2443 2) 2364 / 2443 2) mm 1000x1200 traverse Ast Working aisle width for pallet 800x1200 longit. 2337 / 2146 2) 2337 / 2146 2) mm Wa Turning radius 1488 / 1567 1488 / 1567 mm lowered / raised 1) for 100 mm free lift (h2) 2) DZ + 35 mm 1) for 100 mm free lift (h2) 2) DZ + 35 mm EJC 216 EJC 220 19
c Load centre distance 600 600 mm x Load distance 687 687 mm y Wheel base 1277 / 1357 1277 / 1357 mm h1 Mast height (retracted) ZT 1) 1750-2650 1750-2650 mm h1 Mast height (retracted) ZZ 1) 1700-2600 1700-2600 mm h1 Mast height (retracted) DZ 1) 1830-2250 mm h2 Free lift ZT 100 100 mm h2 Free lift ZZ 1173-2073 1100-2000 mm h2 Free lift DZ 1306-1726 mm h3 Lift (mast-dependent) ZT 2400-4200 2100-3900 mm h3 Lift (mast-dependent) ZZ 2400-4200 2100-3900 mm h3 Lift (mast-dependent) DZ 3990-5250 mm h4 Mast height extended ZT 2927-4727 2750-4550 mm h4 Mast height extended ZZ 2927-4727 2750-4550 mm h4 Mast height extended DZ 4565-5825 mm h13 Lowered height 90 90 mm h14 Tiller height in min./max. travel position 768 / 1298 768 / 1298 mm l1 Length 1896 / 1976 1976 mm l2 Fork length 746 / 826 826 mm including fork shank b1 Truck width 802 820 mm b5 Width across forks 570 570 mm s/e/l Fork dimensions mm b10 Track width, front 510 510 mm b11 Track width, rear 375 375 mm m2 Ground clearance centre 30 20 mm wheelbase Ast Working aisle width with pallet 2364 / 2443 2) 2443 mm 1000x1200 traverse Ast Working aisle width for pallet 800x1200 longit. 2337 / 2146 2) 2146 mm Wa Turning radius 1488 / 1567 1567 mm lowered / raised 1) for 100 mm free lift (h2) 2) DZ + 35 mm 20
3.3 Weights EJC 212 EJC 214 Net weight excl. battery 780 780 kg Axle load, w. load 750 / 1392 760 / 1592 kg front/rear + battery Axle load, w.o. load 665 / 277 670 / 282 kg front/rear + battery Battery weight 162 162 kg 1) Values for standard mast EJC 216 EJC 220 Net weight excl. battery 780 840 kg Axle load, w. load 785 / 1777 938 / 2790 kg front/rear + battery Axle load, w.o. load 675 / 287 690 / 438 kg front/rear + battery Battery weight 162 288 kg 1) Values for standard mast 3.4 Tyre type EJC 212/214/216/220 Tyre size, drive 260 x 70 mm Load section tyre size (single / tandem) 85 x 110 mm Castor wheel 140 x 54 mm Wheels, number front/rear (x = driven) 1 x + 1/2 21
3.5 EN norms Z Z Noise emission level EJC 212 / 214 / 216 / 220: 65 db(a) in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the level of the driver's ear. Electromagnetic compatibility (EMC) The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein. No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer. WARNING! Medical equipment can be damaged by non-ionised radiation Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions. Consult with a doctor or the medical equipment manufacturer to clarify whether it can be used near the industrial truck. 22
3.6 Conditions of use Z Ambient temperature operating at 5 C to 40 C Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations. 3.7 Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose. 23
4 Identification points and data plates 19 18 18 22 20 21 23 24 25 26 27 Item Description 18 Attachment points for lifting by crane (with ZZ mast in the middle) 19 Truck data plate 20 "Do not reach through the mast" warning 21 Do not step under the load handler warning 22 Capacity 23 Serial number 24 Test plaque 25 Battery data plate 26 Decal: No passengers 27 Truck designation 24
4.1 Data plate 28 29 30 31 32 33 34 35 36 37 38 39 Z Item Description Item Description 28 Type 34 Year of manufacture 29 Serial number 35 Load centre (mm) 30 Rated capacity (kg) 36 Output 31 Battery voltage (V) 37 Min./max. battery weight (kg) 32 Net weight w.o. battery (kg) 38 Manufacturer 33 Option 39 Manufacturer s logo For queries regarding the truck or ordering spare parts always quote the truck serial number (29). 25
4.2 Truck load chart X.XXXX.XX.XX 26 3600 1105 600 The load chart (26) indicates the maximum capacity Q (in kg) for a given load centre D (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load. Example of calculating the maximum capacity: With a load centre of gravity distance C of 600 mm and a maximum lift height H of 3600 mm. the max. capacity Q is 1105 kg. The arrow shaped marks ("40" and "40") on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (21). 40 40 26
C Transport and Commissioning 1 Lifting by crane WARNING! Improper lifting by crane can result in accidents The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane. Prevent the truck from striking other objects when it is being raised, and avoid any involuntary movements. If necessary secure the truck with guide ropes. The truck should only be handled by people who are trained in using lifting slings and tools. Wear safety shoes when lifting the truck by crane. Do not stand under a swaying load. Do not walk into or stand in a hazardous area. Always use lifting gear with sufficient capacity (for truck weight see truck data plate). Always attach the crane slings to the prescribed strap points and prevent them from slipping. Use the lifting gear only in the prescribed load direction. Crane slings should be fastened in such a way that they do not come into contact with any attachments when lifting. Lifting the truck by crane Requirements Park the truck securely, (see "Parking the truck securely" on page 51). Remove any mast guards. 18 Tools and Material Required Lifting gear Crane lifting gear Procedure Secure the crane lifting gear to the strap points (18). The truck can now be lifted by crane. 27
2 Transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted. The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings. Use wedges to prevent the truck from moving. Use only tension belts or tie-down straps or with sufficient strength. 41 41 Securing the truck for transport Tools and Material Required Tension belts/tie down straps Procedure Move the truck onto the transporting truck. Park the truck securely, (see "Parking the truck securely" on page 51). Strap the belts (41) around the truck and tension them sufficiently. The truck can now be transported. 28
3 Using the Truck for the First Time CAUTION! Only operate the truck with battery current. Rectified AC current will damage the electronic components. Cable connections to the battery (tow leads) must be less than 6 m long and have a minimum cross-section of 50 mm². Procedure Check the equipment is complete. If necessary install the battery, (see "Battery removal and installation" on page 40) Charge the battery, (see "Charging the battery" on page 35). The truck can now be started, (see "Starting up the truck" on page 48) NOTE Cold store trucks Trucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast. If a truck with cold store oil is used outside the cold store, the lowering speeds may increase. 29
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D Battery - Servicing, Recharging, Replacement 1 Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer s instructions concerning batteries and charging stations must be observed when carrying out the work. Fire protection Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the truck. The room must be ventilated. Fire protection equipment must be on hand. Battery maintenance The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease. CAUTION! Before closing the battery panel make sure that the battery cable cannot be damaged. There is a risk of short circuits with damaged cables. Battery disposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer s disposal instructions must be followed. 31
WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Above all avoid any contact with battery acid. Dispose of used battery acid in accordance with regulations. Always wear protective clothing and goggles when working with batteries. Do not let battery acid come into contact with skin, clothing or eyes. If necessary, rinse with plenty of clean water. Call for a doctor immediately in the event of physical damage (e.g. skin or eye contact with battery acid). Neutralise any spilled battery acid immediately with plenty of water. Only batteries with a sealed battery container may be used. Follow national guidelines and legislation. WARNING! Using unsuitable batteries can cause accidents The weight and dimensions of the battery have a considerable effect on the operational safety and capacity of the industrial truck. Changing the battery features requires the manufacturer s approval, as compensating weights are required if smaller batteries are fitted. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck. Park the truck securely before carrying out any work on the batteries ((see "Parking the truck securely" on page 51)). 32
2 Battery types Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard: Battery type Capacity Weight 24 volt battery 653x207x350 mm (Lxwxh) 3 EPzB 195 Ah 196 kg 24 volt battery 644x207x530 mm (Lxwxh) 3 EPzB 300 Ah 250 kg 24 volt battery 644x205x682 mm (Lxwxh) maintenance-free 24 volt battery 624x284x537 mm (Lxwxh) 24 volt battery 660x146x682 mm (Lxwxh) maintenance-free 24 volt battery 622x281x627 mm (Lxwxh) 24 volt battery 624x284x627 mm (Lxwxh) 24 volt battery 624x284x627 mm (Lxwxh) 24 volt battery 624x284x627 mm (Lxwxh) 3 EPzV-BS 255 Ah maintenance-free 250 kg 3 EPzS 270 Ah 245 kg 3 EPzV 240 Ah maintenance-free 243 kg 3 EPzS 375 Ah 302 kg 3 EPzV 300 Ah maintenance-free 3 PzW 330 Ah maintenance free 200 3 EPzS 345 Ah lib. gold 302 kg 288 kg 295 kg The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulating mat. 33
3 Exposing the battery CAUTION! Trapping hazard Make sure there is nothing between the battery cover and the truck when you fit the battery cover. WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load / load handler is dangerous and is strictly prohibited. Always park the truck on a level surface. In special cases the truck may need to be secured with wedges. Always fully lower the mast and forks. Select a place to park where no other people are at risk of injury from lowering forks. Requirements Park the truck on a level surface. Park the truck securely, (see "Parking the truck securely" on page 51). Procedure Pull out the Emergency Disconnect (battery connector) (45). Open the battery panel (42). The battery is exposed. 42 6 CAUTION! The battery panel is only properly opened if the angle is more than 90. It is then held by gravity. 34
4 Charging the battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. Switch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector. The charger must be adapted to the battery in terms of voltage and charge capacity. Before charging, check all cables and plug connections for visible signs of damage. Ventilate the room in which the truck is being charged. The battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation. Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the truck. Fire protection equipment must be on hand. Do not lay any metallic objects on battery. It is essential to follow the safety regulations of the battery and charger station manufacturers. 4.1 Charging the battery with an on-board charger DANGER! Risk of electric shock and burning Damaged and unsuitable wires can cause electric shocks and can overheat, resulting in fires. Only use mains cables with a maximum length of 30 m. Local regulations must be observed. Fully unreel the cable reel when using it. Always use original manufacturer s mains cables. Insulation safety, acid and caustic ratings must comply with the manufacturer's mains cable. 35
Z NOTE Improper use of the on-board charger can cause material damage. The on-board charger consisting of a battery charger and battery controller must not be opened. For faults, contact the manufacturer s service department. The charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's service department. Batteries must never be swapped from truck to truck. Do not connect the battery to two chargers simultaneously. The factory setting for trucks without a battery is the 0 position. A battery discharge indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached to the connector (47). 46 47 Setting the charging characteristics CAUTION! Remove the mains connector before setting the respective charging curve. Set the charging characteristic Requirements Battery connected. Procedure Turn the setting switch (46) on the charger right to adapt the charging curve to the battery being used. The validity of the new setting is acknowledged by the flashing of the green LED and the setting takes immediate effect. The charging characteristic is now set. 36
Switch setting / charging curve assignment Switch position (46) Selected charging curves (characteristics) 0 Truck without battery NOTE Wet cell battery: PzS with 100-300 Ah 1 Wet cell battery: PzM with 100-180 Ah 2 Maintenance-free: PzV with 100-149 Ah 3 Maintenance-free: PzV with 150-199 Ah 4 Maintenance-free: PzV with 200-300 Ah Wet cell battery: PzS with pulse characteristic 200-400 Ah 5 Wet cell battery: PzM with pulse characteristic 180-400 Ah 6 Jungheinrich 100-300 Ah All other switch positions (46) block the charger, and the battery is not charged. For PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond 180 Ah set characteristic 5. With PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be used. Characteristic 5 achieves a faster charge. When the battery is connected this allows you to adjust via the charger: If the switch position is valid the green LED flashes according to the position set; if the switch position is invalid the red LED flashes. Starting to charge with the onboard charger Mains connection Mains voltage: 230 V / 110 V (+10/-15%) Mains frequency: 50 Hz / 60 Hz The mains cable of the charger (48) is contained in the front panel or the battery compartment. Charge the battery Requirements Park the truck securely, (see "Parking the truck securely" on page 51). Expose the battery, (see "Exposing the battery" on page 34). Correct charging program set on charger. 48 Procedure Remove any insulating mats from the battery. The battery connector must remain plugged. Attach the mains connector (48) to a mains socket. Pull Emergency Disconnect switch up. 37
Z The flashing LED indicates the charge status or a fault (for flashing codes see LED Display table). The battery is now charged. When the mains connector (48) is connected to the mains, all the truck s electrical functions are disconnected (electric immobilizer). The truck cannot be operated. Completing the battery charge, restoring the truck to operation NOTE If charging has been interrupted, the full battery capacity will not be available Requirements Battery charging is complete. Procedure Remove the mains connector (48) from the socket and store it in the battery compartment with the cable. If applicable, place the existing insulating mats back over the battery. Close the battery cover securely. The truck is now ready for operation. Z Charging times The duration of charge depends on the battery capacity. Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging. LED display (49) Green LED (charge status) Lit Charging complete, battery full. (Charge interval, float or compensation charge). Flashes slowly Charging. Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristic curve set. 49 Red LED (fault) Lit Overtemperature. Charging is interrupted. Flashes slowly Safety charging time exceeded. Charging is cancelled. Mains must be disconnected for charging to restart. 38
Red LED (fault) Rapid flash Invalid characteristic curve setting. Compensation charge The compensation charge starts automatically when charging is complete. Partial charging The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum. 4.2 Charging the battery with a stationary charger Charge the battery Requirements Expose the battery, (see "Exposing the battery" on page 34). Procedure Disconnect the battery connector (45) from the truck connector. Connect the battery connector (45) to the charging cable (45) of the stationary charger. Start charging in accordance with the charger operating instructions. The battery is now charged. Completing the battery charge, restoring the truck to operation NOTE If charging has been interrupted, the full battery capacity will not be available Requirements Battery charging is complete. Procedure Complete charging in accordance with the charger operating instructions. Disconnect the battery from the charger. Connect the battery to the truck. The truck is operational again 39
5 Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. Note the "Safety regulations for handling acid batteries" section in this chapter. Wear safety shoes when removing and installing the battery. Use only batteries with insulated cells and terminal connectors. Park the truck on a level surface to prevent the battery from sliding out. Make sure the crane slings have sufficient capacity to replace the battery. Use only approved battery replacement devices (battery roller stand, replacement trolley etc.). Make sure the battery is securely located in the truck's battery compartment. Removing the battery Requirements Park the truck securely, (see "Parking the truck securely" on page 51). Expose the battery, (see "Exposing the battery" on page 34). 50 Z Z Z Procedure Disconnect the battery connector from the truck connector. Place the battery cable on the tray so that it cannot be severed when the battery is pulled out. Strap the crane lifting gear to the eyes (50). The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must never fall into the battery cells. Pull the battery up out of the container. Installation is the reverse order. When reinstalling the battery, note the proper installation position and make sure the battery is connected correctly. Place the battery cable on the tray so that it cannot be severed when the battery is inserted. After installing the battery, check all cables and plug connections for visible signs of damage. 40
5.1 Removing the battery from the side CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. When removing and installing the battery do not put your hands between the battery and the chassis. Battery removal Requirements Park the truck securely, (see "Parking the truck securely" on page 51). Expose the battery, (see "Exposing the battery" on page 34). Procedure Pull the lock on the battery door (52) up. Hold on to the battery door (53) in the meantime. Lift out the battery door (53) and put it in a safe place. Move the battery replacement station / trolley up to the side of the truck. Carefully push the battery from off the truck onto the battery replacement station / trolley. The battery is now removed. Z Battery installation Requirements Park the truck securely, (see "Parking the truck securely" on page 51). Expose the battery, (see "Exposing the battery" on page 34). Procedure Installation is the reverse order. When reinstalling the battery, note the proper installation position and make sure the battery is connected correctly. Push the battery in as far as the battery stop. Apply the battery stop lever (51) and hold it securely. Push the battery into the truck. 41
52 51 53 42
E Operation 1 Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative. Driver s rights, obligations and responsibilities The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operating instructions. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks. Unauthorised use of truck The driver is responsible for the truck during the time it is in use. The driver must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people. Damage and faults The supervisor must be immediately informed of any damage or faults to the truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified. Repairs The driver must not carry out any repairs or alterations to the truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches. Hazardous area WARNING! Risk of accidents / injury in the hazardous area of the truck The hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment. Instruct unauthorised people to leave the hazardous area. Give a warning signal with plenty of time for people to leave. If unauthorised personnel are still within the hazardous area stop the truck immediately. Safety devices and warning labels Safety devices, warning signs ((see "Identification points and data plates" on page 24)) and warning instructions in the present operating instructions must be strictly observed. 43
2 Displays and Controls 54 54 57 58 55 56 57 55 55 56 56 57 58 57 o t 7 9 10, 59 11 12 6 13 44
Item Control / Display EJC EJC 212/214 216/ 220 6 Emergency Disconnect switch Function t t Interrupts the battery connection All electric functions are cut out and the truck decelerates 7 Slow travel button t t If the tiller is in the upper braking zone, braking can be overridden by pressing the switch, and the truck can move with reduced speed (slow travel). 9 Tiller t t Used to steer the truck. 10 Battery charge / discharge indicator t t Battery charge status Battery discharge status. 59 CanDis o o Display instrument for Battery charge status Service hours Warning messages Parameter settings 11 CanCode o o Replaces the key switch The truck is activated when you enter the appropriate code. Travel program selection. Code setting. Parameter setting. ISM o o Replaces the key switch Activates the truck via a card / transponder. Displays readiness for operation. Operating data acquisition Data exchange with card / transponder 12 Key switch and key t t The truck is released when you enter the appropriate code. Removing the key prevents the truck from being switched on by unauthorised personnel. 13 On-board charger o o Charges the battery (see "Battery - Servicing, Recharging, Replacement" on page 31) 45
Item Control / Display EJC 212/214 EJC 216/ 220 Function 54 Warning signal (horn) t t Warning button button 55 Load fork lower switch t t Lowers the forks. The lowering speed can be infinitely controlled by the distance the button is moved (8 mm). 56 Load fork raise switch t t Raises the forks. The lowering speed can be infinitely controlled by the distance the button is moved (8 mm). 57 Travel switch t t Controls travel direction and speed. 58 Collision safety switch t t Safety function When pressed the truck travels for approx. 3 seconds in the fork direction. The parking brake then applies. The truck remains switched off until the controller is briefly restored to neutral. t = Standard equipment o = Optional equipment 46
2.1 Battery discharge indicator When the truck has been released via the key switch, code lock or ISM, the battery charge status is displayed. The LED (60) colours represent the following conditions: 60 Z LED colour Residual capacity Green 40-100 % Orange 30-40 % Flashing green/orange 1Hz 20-30 % Red 0-20 % If the LED is red, load units can no longer be lifted. Lifting is only enabled again when the battery connected is at least 70% charged. If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a truck controller code. The flashing sequence indicates the type of fault. 47
3 Starting up the truck 3.1 Checks and operations to be performed before starting daily operation WARNING! Damage and other truck or attachment (special equipment) defects can result in accidents. If damage or other truck or attachment (special equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired. Report any defects immediately to your supervisor. Tag out and decommission a faulty lift truck. Only return the truck to service when you have identified and rectified the fault. Pre-start inspections Procedure Check the whole of the outside of the truck for signs of damage and leaks. Damaged hoses must be replaced immediately. Test hydraulic system. Check the battery attachment and wire connections for damage and make sure they are secure. Check the battery and battery components. Make sure the battery connector is secure and operating correctly. Check the load handler for visible signs of damage such as cracks, bent or severely worn forks. Check the drive wheel and load wheels for damage. Check that the markings and labels are present, clean and legible, (see "Identification points and data plates" on page 24). Check the control handle (damper) is restored to its normal position. Check the controls are automatically restored to zero after being applied. Test the warning signal. Test the brakes. Test the collision safety switch and Emergency Disconnect switch. Check doors and/or covers. Check the mast guard for damage. 48
3.2 Preparing the truck for operation Switching on the truck Requirements For checks and operations to be performed before starting daily operation, (see "Checks and operations to be performed before starting daily operation" on page 48). Procedure Push the Emergency Disconnect (battery connector) (6) down until it engages. Switch on the truck, to do this Insert the key in the key switch (12) and turn it to the right as far as it will go (position I ) or for CANCODE (11,o) enter the activation code, (see "CanCode keypad" on page 65). Test the warning signal button (54). Test the lifting operation. Test the steering. Test the brake function of the tiller (9). The truck is now ready for operation. tthe battery discharge indicator (10) shows the current battery charge status. o The display instrument (CANDIS) (59) indicates the available battery capacity and the service hours. 49
54 9 10, 59 11 12 6 50
3.3 Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load handler is dangerous and is strictly prohibited. Always park the truck on a level surface. In special cases the truck may need to be secured with wedges. Always fully lower the mast and forks. Select a place to park where no other people are at risk of injury from lowering forks. Parking the truck securely Procedure Fully lower the load handler. Turn off the key switch and remove the key. For CANCODE, press the O key. For ISM, press the red button. Pull out the Emergency Disconnect (battery connector). The truck is parked. 3.4 Battery discharge monitor Z The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries the display and cutout points of the battery discharge monitor must be set by authorised specialist personnel. If this adjustment is not made the battery may become damaged through excessive depletion. If the residual capacity falls below the required level, lifting is inhibited. An alternating display (60) appears. Lifting is only released when the battery connected is at least 70% charged. 51
4 Industrial Truck Operation 4.1 Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials. Additional equipment is necessary to operate the truck in areas of insufficient lighting. DANGER! Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. The driver must ensure that the loading dock / ramp cannot move or come loose during loading / unloading. Travel conduct The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach beyond the working and operating area. Travel visibility The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk alongside the truck as a lookout to observe the travel route while maintaining eye contact with the driver. Proceed only at walking pace and with particular care. Stop the truck as soon as you lose eye contact. Negotiating slopes and inclines Negotiating slopes or inclines is only permitted if they are specifically designed as travel routes, are clean and have a non-slip surface and providing they can be safely travelled along in accordance with the truck's technical specifications. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment. 52
Negotiating lifts and docks Lifts may only be entered if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck. The driver must ensure that the loading ramp / bridge cannot move or come loose during loading / unloading. Type of loads to be carried The operator must make sure that the load is in a satisfactory condition. Loads must always be positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down. Prevent liquid loads from sloshing out. 53
4.2 Emergency Disconnect, Travel, Steering, Braking 4.2.1 Emergency Disconnect (battery connector) NOTE The Emergency Disconnect safety function is performed by the battery connector that can be accessed from the outside. Z Pull the Emergency Disconnect Procedure CAUTION! Accident risk The operation of the Emergency Disconnect (battery connector) must not be affected by any objects placed in its way. Do not use the Emergency Disconnect (battery connector) 6) as a service brake. Pull out the Emergency Disconnect (battery connector)(6). All electrical functions are deactivated. The truck brakes to a halt. Release the Emergency Disconnect Procedure Push the Emergency Disconnect (battery connector)(6) back in. All electrical functions are switched on, the truck is operational again. For CanCode and ISM the truck remains switched off. 4.2.2 Automatic braking Z When the tiller is released it automatically sets itself to the upper brake zone (B) and automatic braking ensues. WARNING! If the tiller moves slowly or not at all to the upper brake zone, the truck must be taken out of service until the cause of this fault is be rectified. Replace the gas pressure spring if necessary. 54